QUALITY CONTROL
A Model Program for the Food Industry
Ingredient Specifications . . . . . . . . . . . . . . . . . 3
Approved Supplier List . . . . . . . . . . . . . . . . . . 5
Product Formulation/Recipe . . . . . . . . . . . . . 6
Product Standards . . . . . . . . . . . . . . . . . . . . . . 6
Manufacturing Procedures . . . . . . . . . . . . . . . 8
In-Process Records . . . . . . . . . . . . . . . . . . . . . 8
Packaging and Labeling . . . . . . . . . . . . . . . . . 9
Good Manufacturing Practices & Sanitation 10
Warehousing . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Laboratory Analysis . . . . . . . . . . . . . . . . . . . 11
Recall Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
The dictionary defines quality as an important
character, a degree of excellence or a necessary attribute.
A group of activities designed to assure a standard of
excellence is called Quality Control.
Food is basic for life. Quality or excellence in our
food supply should be an important concern to all food
processors. Safety and wholesomeness are the most
important attributes of food quality. The lack of quality
as it relates to safety and wholesomeness can result in
personal injury, sick-ness or death. Food-borne illness is
an example of sickness or even death when unsafe foods
are produced and eaten.
Certain foods or food products are defined by
regulations or policies called standards of identity. These
Commitment + Awareness + Teamwork + Communication + Quality Control
= Safe, Wholesome and Consistent Food Products
Figure 1. Quality is everyone’s business. The organizational structure, a reporting system and open communication
are necessary for success.
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standards of identity are definitions for a specific food
product to avoid confusion or mislabeling of similar
processed foods. Milk is a good example. The standard
for skim milk is less than 1/2 percent fat, while the
standard for whole milk is at least 3-1/4 percent fat.
Quality defined by regulations, policies or standards is
controlled by federal and state agencies. Failure to meet
the degree of excellence defined by the regulations,
policies or standards of identity is illegal.
The government-controlled attributes of food are
another important measure of food quality. Therefore,
the first category of food quality is critical attributes
and includes factors that affect safety, wholesomeness or
legality.
Besides the critical attribute of safety, other
properties of the food product should be used to define
overall quality. These other attributes are defined by
industry, the processor or consumer demand. An
example of this is the particle size of flour, the shape of
a frankfurter or sausage or the color and flavor of salad
dressing.
Two other categories that classify or describe
additional quality characteristics of food products are
called major and minor attributes. A major attribute is
determined to be necessary for the food but not essential
from a safety and legal standpoint. A major attribute
could be fat content of hamburger meat or the portion
weight of green peas in a frozen prepared dinner. A
minor attribute is wanted but not absolutely essential to
the product or not easily determined. For instance, the
desirable flavor properties of foods are highly subjective
(dependent upon people), not easily measured and
should be a minor attribute. However, flavor defects that
can reduce sales should be classified in the major
category.
The critical, major and minor attributes usually
describe the key chemical, physical, and microbiological
properties of a food. The manufacturing process and
many known or unknown factors will affect the finished
product. Therefore, a control program is the tool for the
food processor to use to assure that quality targets are
met.
Finally, to develop a quality control program, you
must define expected food quality to provide a system of
quality measurement, allow a means for action not
reaction, help to minimize costly errors, and reduce the
risk of food safety and wholesomeness defects. What is
needed for a quality control program? The first step is a
strong commitment from management. Quality control
must have the same priority as the profit and loss
statement for the business.
Quality doesn't cost, it pays. Beyond commitment,
management must instill quality aware-ness throughout
the organizational structure. A successful quality
program needs people. It is important that the food
operation personnel function as a team and openly
communicate to identify problems, issues or
opportunities. Once key elements of a quality control
program are in place (management commitment, quality
awareness, a team effort and open communication),
develop and use additional tools.
The basic tools of quality control are:
G Ingredient Specifications
G Approved Supplier List
G Product Formulas
G Product Standards (Specifications)
G Manufacturing Procedures
G Critical Control Point Identification/Sampling
Program
G In-Process Analysis, Records and Reporting
Packaging Specifications
G Label Specifications
G Cleaning and Sanitizing Program
Figure 2. Dry Ingredient Storage Area. Keep
materials, ingredients and supplies off the floor and
in closed containers. Repair torn bags.
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G Good Manufacturing Practices (GMP) Requirements
G Recall Program
G Warehousing, Shipping and Receiving Program
G Laboratory Analysis
Ingredient Specifications
The quality of the finished food product after
manufacture depends on the quality of the raw materials
and ingredients. The best starting point for developing
ingredient specifications is the supplier. Ask for a copy
of the supplier's ingredient specifications. Review the
information and modify the specifications to your needs.
Discuss and settle specifications with the supplier. At
times, specifications need to be negotiated with
suppliers. Custom specifications from suppliers are
possible. The ingredient specifications should be
documented in a form consistent with the processor's
needs. Ingredient specifications document should
include:
G Name of Ingredient
G Internal Code Number
G Effective Date
G Basic Description of Ingredient
G Specifications categorized as:
G Critical
G Major
G Minor
G Action and Reject Levels
G Ingredient Statement
The prepared ingredient specifications become a tool
for control. The information under each heading should
be simple but informative. Figure 3 is an example of an
ingredient specification. It is simple and informative.
The basic description is short and to the point. Critical
specifications include two items associated with public
safety. Critical specifications can also include factors
influencing wholesomeness or legality. Action levels are
used as a reference point to identify a potential problem.
If the ingredient consistently reaches action levels, notify
your supplier. The reject level is the point of refusing
delivery of the ingredient. The ingredient statement for
the raw material is a reference point to assure that the
supplier has not changed the material. The final key
point for ingredient specifications is for the supplier to
know and agree to the content of the document.
 GROUND BLACK PEPPER
CODE NUMBER: A-001
PRODUCT DESCRIPTION: Ground black pepper shall be prepared from the dried, immature berries of
Piper nigrum. The color can vary from light-gray to a speckled black-gray.
EFFECTIVE DATE: Today's date
CRITICAL SPECIFICATIONS: Action Level Reject Level
Salmonella none Positive in 100
E. Coli none Positive
MAJOR SPECIFICATIONS: Action Level Reject Level
Granulation 4.5% (retained on a U.S. >5%
#35 sieve)

Volatile Oil 2.5% <2%

Moisture 11.5% >12%
Color light-gray to black-gray off-white to light gray
Yeast/Mold <100 per gram >100 per gram
MINOR SPECIFICATIONS: None
INGREDIENT STATEMENT: Ground Black Pepper
Figure 3. An Ingredient Specification Document

The approved supplier list should contain the

Approved Supplier List
For each ingredient, an approved supplier list should
exist and be available to individuals responsible for
purchasing and quality control. In theory, more than one
supplier per ingredient is desirable. A good target is
three suppliers per ingredient. A supplier is an ingredient
manufacturer, a broker or a distributor. When necessary,
identify both the manufacturer and distributor on the
approved supplier list.
Approve all sources of supply only after careful
evaluation and review of their performance in the
product. For approving alternate ingredient sources two
key questions are:
G Does the ingredient meet the existing or needed
specifications?
G Does the new ingredient provide the same or desired
finished product?
At times, only one acceptable supply source may be
available because of special requirements. In this case,
alternate sources should be listed for emergency
purposes. The emergency source of the ingredient should
be one that has been tested and best approaches all
specifications.
following information:
G Ingredient Name and Internal Code
G Supplier Name, Address, Key Contact and Phone
Number
G Trade Name of Ingredient
G Supplier Code Number
Product Formulation/Recipe
Proprietary formulas are important. For each food
product, written documentation of the formula or recipe
should exist and be available for use by selected
individuals. The formulas should be used daily as a
means to assure consistency between batches, lots and
even days of production. Manufacturing personnel need
to know the recipe to assure that the product is
formulated correctly. For highly confidential formulas,
the production worker does not need all the details. A
simplified recipe can be provided to assure that the secret
stays a secret.
The individual formula sheets can have a variety of
formats. Key aspects of any formula document are:
G Name of the product.
G Internal code number.

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 Effective date.
G
G Listing of the ingredients.
G Listing of the ingredient code.
G Percentage formula.
G Batch formula.
G Batch yield.
G Ingredient statement.
Additional information that can be part of a formula
document are packaging, lot size, regulatory constraints,
net weight, package count per batch, etc. Be flexible with
the format since the formula may purposefully be
modified and the kind of information needed may change.
If nothing else, the batch size may change due to business
growth or decline.
Figure 4 is an example of a formula sheet.
Product Standards
A key tool to assure quality in a finished processed
food is the product standard document. Product
standards define the food by physical, chemical and
microbiological characteristics. Appearance, aroma,
flavor and texture can and should also be considered for
product standards.
Physical characteristics include size, shape,
dimensions, weight, volume, count per package or
container, presence of fines, or any other special features
which define the particular food. Moisture, fat, protein,
ash, fiber and carbohydrates are the basic chemical
characteristics. Additional chemical criterion such as
salt, sodium, cholesterol, etc., are used to chemically
define food products. Chemical standards are necessary
when using nutritional labeling or making label claims
for low sodium, higher fiber or other nutritional facts.
Microbiological standards will be dependent upon
the specific food item. First consider food poisoning
organisms when developing product standards for a
quality control program. Food safety is the responsibility

CHILI WITHOUT BEANS

CODE NUMBER: B-001
EFFECTIVE DATE: Today's date
Ingredients Code % Formula Batch Formula (lbs.)
Beef, 75% lean A-002 40.00 240.0
Tomato Paste, 32% T. S. A-003 11.74 70.4
Water A-004 40.00 240.0
Spice Premix C-001 3.93 23.6
Corn Starch A-005 4.33 26.0
100.00 600.0
Spice Premix C-100
Chili Powder A-006 31.75 7 lb. 8 oz.
Salt A-007 21.17 5 lb.
HVP A-008 19.05 4 lb. 8 oz.
Sugar A-009 12.70 3 lb.
Cumin, grd A-010 6.35 1 lb. 8 oz.
Onion powder A-011 5.85 1 lb. 6 oz.
Oregano, grd A-012 2.37 9 oz.
Garlic Powder A-013 0.76 3 oz.
100.00 23 lbs. 10 oz.
Batch Yield: 600 lbs.
Finished Product Yield: 595 lbs.
Ingredient Statement: Beef, Water, Tomato Paste, Corn Starch, Chili Powder, Salt, Hydrolyzed Vegetable Protein, Sugar,
Spice, Onion Powder, Garlic Powder.

Figure 4. A Food Product Formula Document.

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 GRAVY AND BEEF TIPS
CODE NUMBER: B-002
EFFECTIVE DATE: Today's Date
PRODUCT CODE: 1743
Critical Standards Standard Method
Meat Content minimum of 35% meat (fresh basis) Process Date
Salmonella negative in 100g #100
C. perfringens <10/g #101
Staphylococcus (coagulase positive) <10/g #102
Major Standards
Meat chunks size 3/8" to 5/8" chunks #200
Gravy color (#3, 4 or 5) Color Chart
Coliforms <10/g #103
E. coli <10/g #104
Minor Standards
Gravy Texture a smooth consistency & free of lumps #300
Product Flavor a mild meaty flavor & aroma #301
Standard Plate Count <25,000/g #105
Ingredient Statement: Water, beef, flour, tomato paste, corn starch, salt, HVP, spices, sugar.

Figure 5. Food Product Standards Format

of the processor. If the food product will support the
growth of a potential food poisoning organism, identify
the particular organism in the critical standards category
as opposed to a major or minor standard.
Some typical food poisoning organisms are
Salmonella, Clostridium botulinum, Staphylococcus
aureus and Clostridium perfringens. Other
microbiological standards such as a standard plate count
(SPC), yeast or mold may be appropriate for classification
as major or minor standards. For many products,
especially those subjected to cooking or other thermal
processes, use Coliforms and E. coli analyses to show and
control post process contamination of cooked foods.
Consider microorganisms that can cause food spoilage in
a particular food product when establishing product
standards. Yeast and mold counts are essential to control
programs involving food items with low or restricted
moisture levels like flour or cereals. A simple standard
plate count is always a good general indicator for tracking
bacterial quality and should be considered at least a minor
criterion.
The sensory properties of a food product are keys to
the consumer acceptance. Flavor, texture, aroma and
appearance are criterion that should be defined to assure
that the product meets design expectations. Qualitative
measures of sensory properties can be costly due to
requirements for sophisticated equipment. Qualitative
testing using taste panels, is an alternative to quantitative
measurements. Make a sensory evaluation for flavor,
odor and texture a part of a quality control program.
Establish a reject level for each product standard
along with acceptable methodology. Base minimum
reject levels upon regulatory requirements and practical
production experience. If a method of measurement is
nonexistent, then the standard is nonexistent.
The last element to product standards is a simple
statement of ingredients as it will appear on the label.
Figure 5 shows a format for product standards.
Manufacturing Procedures
For each product, document the method of
fabrication or processing procedures to ease duplication
from lot to lot, shift to shift and day to day. A simple
way to approach this is a clear and concise "cookbook"
approach. Key steps in the process which can impact
upon yield, quality or production efficiency should be
highlighted. Examples of key process steps might be
"mix for 3 minutes before adding spices" or "cook to a
minimum internal temperature of 145 degrees F."
Several key points to consider when identifying

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 Breaded Squash
Description: MANUFACTURING PROCEDURE
Date of Issue: Today’s Date
Authorized Products: Code #1234

Critical process control points are in italics.

1. Remove stems and trim back blossom ends about ½”. (#1) Operator shall trim away all damage caused by rot, insects, or
mechanical abuse; QC shall monitor.
2. Wash the squash, rinse and sanitize with water containing 125 parts per million (ppm) chlorine for five (5) minutes. (#2)
Operator shall adjust chlorine level; QC shall monitor.
3. Cross-cut squash into 3/16" thick slices.
4. Prepare batter according to Formula B-101. Load breading (Code 123) into breading machine.
5. Pass slices through the first batter/ breading operation. (#3) Batter viscosity shall be 80 ± 20 centipoise at 50°F. (Spindle
#5, speed 50 on Brookfield Viscometer, Model RV) Operator shall adjust as required; QC shall monitor.
6. Pass battered/breaded slices through second batter/breading operation. (#4) Batter viscosity shall be 80 ± 20 centipoise
at 50°F. (Spindle #5, speed 50 on Brookfield Viscometer, Model RV) Operator shall adjust as required; QC shall monitor.
Every four hours, discard batter in second batter reservoir.
7. Freeze breaded pieces using spiral freezer. (#5) Packout group leader shall insure all product is solidly frozen before
placing in boxes. QC shall monitor.
8. Prior to packing each lot, adjust tare on scale as determined by the average weight of 10 containers on this day. (#6) QC
shall record the average container weight of 10 containers every day. Pack frozen squash into four-pound boxes. #7) QC
shall check five boxes per day for net weight (4 lb.) And one box per day for piece count. (#8) Group leader shall record
all in-process data (chlorine level, batter viscosity, net weights) in process log.
9. Pack six boxes per shipping crate. Store in holding freezer at 0°F.

Figure 6. Manufacturing procedures for use by production and QC personnel

important processing operations are time, temperature, balance and rework are examples of measurements made
equipment required, order of addition for ingredients and during the manufacturing process. Base the kinds of in-
weight. process measurements used in each operation upon what
Manufacturing procedures also should include special is called Critical Control Points.
instructions to the line worker or quality control A critical control point is a step in the process or in
personnel. An example instruction could be, "cross product formulation where small differences, changes or
check" the net weight of five packages every hour. Figure mistakes can cause the finished product to be a health
6 shows a simple manufacturing procedure to be used by hazard, illegal or costly to the business. Critical control
production and quality control personnel. points are identifiable (Figure 6). Some critical control
Once prepared, make manufacturing procedures or points are defined by regulation when public health or
portions of the procedures available to production
employees. Use the document as an employee training
tool.
Even with the best procedures, employees will find a
"better" way to manufacture the product. Be open minded.
If the new way is better, use it; if not, explain why. The
key is for the employee to follow instructions.

In-Process Records
It is important to know what is happening with the
product and process during manufacturing. In-process
record keeping is a way of obtaining the information.
Both quality control and production personnel should
participate in maintaining a daily manufacturing log. The
specific product weight, temperature, size and shape, Figure 7. In-line check weight of packaged
ingredient usage, product yield, scrap or waste, material product.

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Figure 8. Critical Control Points from a Fresh Cucumber Process.

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 Figure 9. Employee records product change-
over on in-process recording chart. Record
processing data during operation, not at the
end of the day.
product identity are of concern. Cooking temperatures,
pasteurization time and temperature or allowable levels of
ingredients are processing variables oftentimes defined by
regulation.
Critical control points may be self-imposed because
of desired label statements on the part of the processor.
Net weight is one example while nutritional labeling is
another. The cost of a product can be increased by simple
employee mistakes. In this case, critical control points in
processing simply relate to those processing steps that
influence yield or inferior product.
In-process record keeping can be a manual or
automatic operation and in some cases both. Employee
participation in record keeping provides an opportunity
for pride in workmanship. In-process records also are a
means of making adjustments to the product or process
and preventing substandard product.
Turn in all in-process records to supervisory
management for review at the end of a shift or working
day. The supervisory review allows an opportunity to
identify problem areas and to make changes to prevent
reoccurrence. In some food processing operations, like a
poultry or red meat facility, these records are available to
the on-site USDA inspector.
Packaging and Labeling
A quality control program should include packaging
and labeling. One of the first items that influence the
consumer is the appearance of the package and the label.
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Figure 10. Review and summarization of in-
process data is necessary to minimize the change
of a problem reoccurring.
Two basic packages are typically necessary for food
products. The primary package encloses the food and has
direct contact with the product. A film, jar, bottle, carton
or box are some of the common primary packages. The
secondary package is used to assemble multiple
packaged food items for shipment. The shipper or
secondary package provides protection, reduces handling
of each individual bottle or carton and is necessary for
efficient movement of goods to the consumer. Some
packaged foods, particularly microwaveable products,
have three package components: the pouch, the carton
and the shipping case.
Poor packaging or labeling can create negative
impressions relative to product quality. This is true for
both simple and complex packages or labels. Packaging
serves to protect the food product and allows shipment
of multiple units. Items for packaging consideration are:
1. A statement from the supplier that the packaging is
made of FDA and/or USDA approved materials. The
package composition should be listed on the
statement.
2. Dimensions of carton, jar, bottle or box.
3. Strength of the container and suitability for stacking,
freezing or microwaving.
4. Strength of seals or fit of the lid. For heat sealed
packages, the temperature requirements for sealing
are critical.
5. Ability to restrict or allow air flow, moisture or
light. Permeability, thickness, flexibility and
temperature resistance are specific criteria in this
category.

Figure 11. Attractive food packaging protects
contents and helps assure customer satisfaction.
6. Graphics (illustration, picture or visual designs).
7. Label format and legal requirements.
Packaging must be selected or designed based upon
the particular food item. Fresh fruits and vegetables
require packaging that provides protection while allowing
air flow for proper cooling and respiration. Dairy products
require packaging to inhibit light penetration and
excessive oxygen because of the potential for flavor
defects due to oxidation, rancidity or the absorption of
foreign flavor. A final example, the tea bag must provide
permeability to moisture.
Package graphics, by words or pictures, define the
contents and serve as point of purchase information. The
law requires product name, ingredient statement and
manufacturing or distribution location to be on the
package. Government regulations list many requirements
for packaging and even extend to specifying the size or
type or printing. Pictures or other graphics are optional
and serve to inform the consumer. Overall graphics must
represent the contents of the container so mislabeling or
misbranding does not occur. Some typical package and
label defects are smears, scuffs, color variations, broken
seals leaks, short fill and product infestation or spoil age.
The defects can be found in both single unit packs and
multi-packs (shippers).
It is to a food processor's advantage to develop
packaging and label specifications along the same format
as ingredient specifications.
Materials of construction are particularly important
where direct contact with the food is involved. Certain
chemicals or foreign materials from packaging materials
can contaminate the food product. The packaging material
must meet FDA and/or USDA requirements. Use a
reputable packaging supplier. The manufacturer of the
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package is the main source for package specifications.
Local distributors can obtain the needed information
from the manufacturer.
Dimensions of the package, both inner and outer, are
defined to prevent problems such as under or over-fill,
shifting within the package, spillage or breakage of the
container. Lack of control can be costly for product loss,
giveaway or lost sales.
The strength of the container and the seals or the fit
of the lid are important considerations. Failure with
regard to these items can result in crushing, breakage or
spillage. Most important is the potential for physical or
microbiological contamination when a poor seal of
improperly fitting cap is a package defect.
Good Manufacturing Practices
and Sanitation
Federal regulations define specific procedures to
minimize the contamination of food products by people
in manufacturing, processing packaging and
warehousing facilities. The regulations are called Good
Manufacturing Procedures (GMPs). GMPs are an
integral part of quality control. It is the respons-ibility of
food business management and ownership to know,
practice, communicate and ensure that GMPs are carried
out by employees. An overview of GMPs is as follows:
1. Individuals with communicable diseases cannot
work in areas where food contamination is possible.
This includes individuals with boils, sores or
infected wounds.
2. Food handlers must follow good personal hygiene
practices.
a. Wear protective clothing.
b. Clean and sanitize hands and gloves.
c. No jewelry.
d. Use gloves (non-absorbent) when the job
requires hand covering.
e. Use effective hair restraints and covering.
f. Eat, drink or smoke only in designated areas.
3. Train employees effectively in hygiene, sanitation
and pest control.
Along with GMPs, a cleaning and sanitizing
program is essential. Cleaning and sanitizing should
address three basic areas:
1. Exterior facility and grounds.
2. Internal facility including floors, walls, ceilings and
ventilation system.
3. Equipment and all food contact areas.

Figure 12. Employees wear gloves, hair covering and
protective clothing to assure food safety.
A cleaning and sanitizing program prevents the build
up of dirt and debris, maintains equipment in good repair,
prevents growth and contamination from microorganisms
and prevents the entry and harboring of insects and other
pests. The quality program should: outline specific
activities to be performed, any corrective measures,
schedules for cleaning and sanitizing, identify approved
cleaning compounds, sanitizers and baits and define a
standard. Keep and maintain proper records.
Warehousing
Warehousing involves three activities (receiving, storage
and shipping) that are included in a quality control
program. The receiving operation is the foundation for
processing finished food products of a designated quality.
Guidelines for incoming shipments are:
1. Be sure the storage space is clean and consistent with
the first-in-first-out rotation principle. FIFO or first-
in-first-out rotation is the removal of inventory from
storage in a systematic way where earlier stock items
are used first. This can be accomplished by date
coding the inventory according to the date of receipt.
2. Before unloading, inspect the condition of the carrier.
Measure temperature, observe and note foul odors,
spills, and insects. For refrigerated and frozen
products, temperature is critical.
3. Observe the condition of the containers for damage
which could be a source of contamination.
4. Collect random samples from the shipment and
analyze or evaluate the samples in relation to
specifications.
5. After unloading, inspect the condition of the carriers
and notice the condition of the floors and walls. Take
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note of any dirt, filth or residues and evidence of
previous spills.
6. Do not accept food, ingredient or packaging
shipments combined with chemicals or poisonous
substances.
7. If the shipment does not meet specifications, be
prepared to reject all or part of the load.
8. Minimize dock time. Move refrigerated or frozen
items directly into storage.
9. Date code all incoming shipments directly on the
container or pallet load for stock rotation.
Improper storage can adversely impact upon the
quality of materials, ingredients and finished product.
Storage in an orderly manner under proper conditions of
temperature and humidity is essential to quality. Certain
supplies or ingredients may require segregation.
Rotate the inventory. If not properly managed items
may ruin in storage areas.
Shipping is the final step in which a food business
can have direct control on product quality. Ship items on
a first-in-first-out basis and use the same guide-lines in
shipping that you followed in receiving.
Laboratory Analysis
The establishment of specifications and standards is
meaningless without laboratory analysis or an evaluation
program. Laboratory analysis is the phase in which a
quality control program is implemented after product is
produced. A sampling plan, along with an analysis
frequency (time schedule defining how often analyses
are made), is absolutely necessary.
Compile the methods of analysis used in the
laboratory in a special working notebook. Micro-
biological, chemical and physical analyses of food are
available in the book, Official Methods of Analysis,
published by the Association of Official Analytical
Chemists. For some analyses, very simple methods are
used in the laboratory. By example, for fruits or
vegetables, color measurements and physical defects are
sometimes determined by comparing the product to a
chart. Other methods like a protein or fat analysis are
more complicated and require specialized equipment.
Microbiological methods performed on product
whether it is poultry, red meat, dairy, vegetable or
seafood also requires special instruments and equip-
ment. Incubators and an autoclave are necessary in
microbiological analyses. An incubator is used to control
temperature conditions and allow bacteria to grow so
groups of bacteria (colonies) can be counted. An
autoclave is like a steam cooker. This piece of equipment
is used to sterilize laboratory glassware and destroy
bacteria, yeast or mold after an analysis. Destruction of
the microorganisms is important so safe disposal is
possible.
Perform all laboratory analyses in a room away from
the processing area. At times, a small food plant may not
have a separate area. Therefore, there are three ways to
obtain laboratory analysis results:
1. In-house lab.
2. Outside independent lab.
3. Combination of in-house and independent lab.
Appoint a qualified individual to conduct analyses,
report the results and manage the job of quality control.
Have laboratory tests results recorded and compared to
the specifications or standards. Deviations from standards
should be communicated so that additional action can be
taken if necessary.
Many methods exist for the laboratory analysis of
food. Examples of some methods are:
G Standard plate count, a microbiological method used
to count the numbers of bacteria contained in a
product.
G Yeast and mold count, a microbiological method used
to count the number of yeast and mold in food.
G A chemical method (pH) which determines if a food
is acidic, neutral or basic.
G Moisture, a chemical method to determine total water.
G Protein, a chemical method to determine the protein.
G Fat, a chemical method to determine total fat.
Recall Plan
Product recall is having to bring back product from
the distribution system. Every food business is susceptible
to potential product recall. The public image of businesses
can be destroyed during a recall if a well-organized plan
is not implemented.
Why would a product be recalled? Products are
recovered from distribution as a result of voluntary action
by a business firm or involuntary action due to Food and
Drug Administrative (FDA) action. The basic reasons for
recall are best described by the FDA recall classifications:
CLASS 1 - As a result of a situation where there is
reasonable probability that the use or exposure to a
defective product will cause a serious public health
hazard including death.
CLASS II - As a result of a situation where the use of
or exposure to a defective product may cause a
temporary adverse health hazard or where serious
adverse public health hazard (death) is remote.
CLASS III - As a result of a situation where use of or
exposure to a defective product will not cause a
public health hazard.
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An example of Class I product recall would be
contamination with a toxic substance (chemical or
microbiological). A Class II product recall is where
product is contaminated with food infection
microorganisms, while a Class III example is where
product does not meet a standard of identity.
Because of recall potential, a food business firm
must be prepared for the worst situation. A recall plan
should be developed and communicated to appropriate
individuals within the firm before an emergency arises.
The plan should include:
G An effective product coding system. Coding should
be simple, yet broad enough to minimize financial
loss. Date of manufacture, date code plus shift code,
lot code or various combinations are possible.
G A record keeping system to identify and associate
specific product, product code, carrier and
destination.
G A list of key personnel and their assigned
responsibilities for a recall. Select key personnel
from each of the following areas: production, quality
control, marketing, shipping/receiving and legal
counsel.
G A communication system within the firm and a
system into the distribution marketing shipping/
receiving channels and legal counsel. A
communication system is critical to minimize rumor
and the exaggeration or misstatement of the facts in
and out of the business.
G Established procedures for evaluating and correcting
situations.
A good recall program is like an insurance policy.
The program will not prevent an adverse situation from
occurring. It will, however, help the business and
personnel prepare for a possible recall.
Food quality is an expectation of consumers. To
meet this consumer need, every food business should
develop and use an effective quality control program.
Failure to meet consumer demand can cause a decline in
product sales and profitability. A major product failure
can totally destroy a business. Start or update quality
control practices now, and continue to build the program
for the future. In case there is doubt, ask two questions:
1. Are we doing things right?
2. Are we doing the right things?
 References
How to Prepare A Quality Assurance Plan, Food Warehousing. Department of Health and Human Services, Public
Health Service, U.S. Food and Drug Administration.
Gravani, Robert B. Food Science Facts for the Sanitarian, Dairy and Food Sanitation. April 1986.
Rust and Olson. Coping With Recalls, Meat and Poultry Vol. 33, No. 3, March 1987.

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Prepared by Philip T. Tybor, William C. Hurst, A.E. Reynolds and G.A. Schuler of the Extension Food Science and
Technology Department.

Bulletin 997 August 1988, Reprinted February 1997

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